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SuspensionPart report

2004 Ford Excursion Suspension Problems

Complaints
3about this part
Share
3%of 95 total for the year
Median mileage
169,000miles
Trend
Not enough dataFewer than 15 complaints, too few for a reliable trend.

NHTSA recorded 3 complaints about the suspension of the 2004 Ford Excursion, 3% of the 95 complaints for this model year. Where a mileage was given, the median is 169,000 miles.

Fewer than 15 complaints name this part, so treat the figures as a rough indication only.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“The contact owns a 2004 Ford Excursion. The contact stated the steering wheel felt loose while driving approximately 25 MPH. The failure began to recur while driving at various speeds. The vehicle was taken to an auto shop where the contact was told that there was a crack on the front passenger side stabilizer bracket. Crack was welded and a gusset was applied between the bracket and front axle. The failure and current mileages were 169,000. …”

NHTSA complaint #10399648, filed 2011-05, 169,000 miles

“We purchased 2004 Ford Excursion with the 6.0l diesel engine new in february 2004. It has been to the dealer now 2 times for the back up sensor, approximately 5 times for the turbo, unable to count the number of times for the lack of power, the vent windows not working, 3 times for the motor on the power drivers seat, ball joints 1 time, and now other front end parts. This vehicle is primarily used to go to church and travel with the entire family on the weekends for day trips. …”

NHTSA complaint #10244578, filed 2008-10

“My 2004 Ford Excursion 4x4 with the 6.0 psd has approx. 1/2 clearance between the front springs and the spring bump stop. The passenger side has about 1 . The only allows the suspension to travel 1/2 and 1 . During normal driving it will very often bottom out onto the 3 rubber bump stops putting the weight of the truck bouncing on the axles and tires. During normal driving, when it bottoms out, steering control is minimal as the shock to the vehicle is significant and the shock of the weight is primarily on the tires. …”

NHTSA complaint #10060741, filed 2004-03

Suspension: other model years

YearComplaintsShare of year
200512%
200433%
200366%
200254%
2001147%
2000357%
1999229%

Other parts of the 2004 Ford Excursion

Engine cooling
22 complaints
Electrical system
21 complaints
Fuel system
12 complaints
Vehicle speed control
9 complaints
Engine
7 complaints
Transmission and drivetrain
7 complaints
Tires
6 complaints
Brakes
5 complaints
Visibility (wipers, defrost, mirrors)
5 complaints
Air bags
3 complaints
Exterior lighting
3 complaints
Latches, locks and linkages
3 complaints

← All problems reported for the 2004 Ford Excursion

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 27, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology